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Exercise bike powered electric generator for fitness club appliances

Conference Paper · October 2007

DOI: 10.1109/EPE.2007.4417471 · Source: IEEE Xplore

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Ryszard Michal STRZELECKI Marcin Jarnut

Gdansk University of Technology University of Zielona Góra
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 Exercise bike powered electric generator for fitness club appliances

R. Strzelecki1, M. Jarnut2, G. Benysek2

1
GDYNIA MARITIME UNIVERSITY, Department of Electrical Engineering
Morska 81-87 street, 81-225 Gdynia, POLAND
Tel.: +48 / (0) - 586901204
Fax.: +48 / (0) - 586901445
E-Mail: rstrzele@am.gdynia.pl
URL: http://am.gdynia.pl
2
UNIVERSITY of ZIELONA GÓRA, Institute of Electrical Engineering
Podgórna 50 street, 65-246 Zielona Góra, POLAND
Tel.: +48 / (0) - 683282538
Fax.: +48 / (0) - 683254615
E-Mail: M.Jarnut@iee.uz.zgorz.pl
E-Mail: G.Benysek@iee.uz.zgorz.pl
URL: http://www.iee.zu.zgora.pl

Keywords
Converter circuit, Energy storage, MOSFET.

Abstract
A generator powered by a stationary bicycle for the purposes of generating electricity for fitness club
appliances is considered. A generator is connected to a stationary bicycle in such a way as the circular
rotation of the front wheel rotates the coils of wires inside the generator between the poles of the
magnets inside the generator. The resulting Direct Current is channeled to the attached battery bank
and converted into different usable DC voltage levels as well as AC voltage, just to increase the
number of electrical appliances possible to connect.

Introduction
In the modern age, there are more and more electrical devices which do the work that human beings
once had to do physically. As more people spend more and more of their days in front of computers or
any other equipments without any movements, additional concerns, such as health and the exercise
they need for healthful living are often overlooked. From the other side for people who want to be
aerobically fit it's not common to spend hours for example pedaling an exercise bicycle that produces
nothing but heat, why not have your-my-our workout and generate usable electricity at the same time.
A exercise bike powered electric generator provides a method of generating electricity by means of a
modified stationary bike for use in electrical energy storage and running household or other
appliances. Human/mechanical energy is converted into electrical by means of a electric generator that
is connected to an exercise bike flywheel. As result the energy created by the generator can be stored
in various types of lead-acid batteries which may then be tapped at a later time, after dark for example,
when the energy is needed to power lights or else. If AC appliances are in place then a inverter must
be used to transfer the DC current into the standard 230 volts of AC current for usage by these
appliances.
Every one is probably wondering, “can I generate all my needed electricity with a stationary bicycle?”.
Tests on exercise bicycles showed that 75W of power is possible to be generated by an average rider at
road speed in a one hour time frame. It was also found that at 25kph it is possible to achieve 200W for
short periods, while 750W is possible only for a second or so, under extreme load. These results show
that human/mechanical energy, if harnessed could be added to novel or existing battery banks and then
could be set up to run appliances. Appliances that could be powered, that draw small amounts of
current, include VHF/UHF radios, laptops, stereos, high efficiency fluorescent lightings which allow
for example 200W to go a long way (a typical 25W fluorescent light bulb, which replaces a 100W
incandescent bulb, will last 8 hours on 200W worth of power) and finally LEDs (Light Emitting
Diodes) which are even more efficient and will last days on 200W worth of power (a few minutes of
pedaling would be enough to create hours of light).
On the base of above the answer to earlier asked question is yes. Yes, for a household with more than
four family members that do not use much electricity, and are in average physical condition. Therefore
the perfect place to apply the exercise bike powered electric generator could be a fitness club, where
are usually at least few bikes and many energized people who want to be fit.

Example of potential use

This section provides an example of the electrical output that is possible with stationary bike powered
electric generator and the energy consumption in exemplary fitness club. On the base of measurements
which were made in considered fitness club, we do know that:
• The total electrical energy consumption during 1year (295 working days) is about 4800kWh
• Every single exercise bike works at least 6 hours every day, with average speed of 20kph.

For calculations we assumed the 10kg and 40cm diameter flywheel. For given data we were able to
determine the kinetic energy of the flywheel. During 1min that is [2]:

K = 1 ⋅ m ⋅ r 2 ⋅ ω 2 = 1 ⋅ 10 ⋅ 0.2 2 ⋅ 264 2 = 13939 J (1)

2 2

where: ω = 264 rpm.

After simply calculations energy produced by single bike during one hour is [3, 4]:

W = 13939 ⋅ 2.7778 ⋅ 10 −7 ⋅ 60 = 0.232 kWh (2)

and during one cycle of work (6 hours) 1.38kWh. Considering fact that in “our” fitness club are five
bikes, there is possible to produce more than 2000kWh energy during one year, what possibly covers
about 42% of the whole energy consumption. Hoverer every one hast to keep in mind that these
numbers do not include the loss of efficiency that is created when electricity is converted to different
DC voltage levels and to AC voltage.

Alternator
swON ⇒ PM > 0
G voltage
regulator swOFF ⇒ PM = 0

Bank of batteries Converter C1 Inverter

Alternator 12 V 24 V
Bat Bus DC Bus AC Bus
+ -
PG I DC
G voltage
regulator
12 V u AC
UG 120Ah
24 V 230 V
Loads
U Bat Controller iL
48 V
Loads
Alternator
Loads
I L− DC
U DC AC Mains sw
G voltage
regulator
24 V
Converter C2 Loads iM PM

Fig. 1: Exercise bikes powered electric unit

Exercise bike powered electric generator - construction
Now that the potential power output has been defined this is possible to design a human powered
electrical energy generator. Components needed to build the DC and AC unit, see Figure 1, include: i)
exercise bike: a front mounted wheel with a channel, the generator pulley is at 5cm diameter; ii)
generator: 750W and 12VDC auto-alternator with voltage regulator (limits amount of current flow
when battery reaches full charge to prevent damage to battery) where the level of load is varied
through generator’s excitation current changes [1, 5]; iii) 12V and 120Ah lead-acid auto battery; iv)
set of DC/DC converters: the first one 12/24VDC (1.5kW) keeps (during PM=0 mode) constant DC
Bus voltage, therefore directly secures proper operation of the 24VDC loads and indirectly 48VDC
loads as well as 230VAC loads; during PM>0 mode C1 converter is turned off; the second one
24/48VDC (0.5kW) is supplied from the common DC Bus and provides power to 48VDC loads during
both operation modes (PM>0 and PM=0); v) the inverter (1.5kW) changes the 24VDC into standard
230VAC and provides power to the AC loads; the challenge with using the inverter and keeping it in
the off-line operation mode (PM=0) is to hold the DC Bus voltage above level, or else the inverter will
go into on-line operation mode (PM>0).

Control panel

Generator
Inverter

Converters

Voltage
Regulator

Battery

Fig. 2: Laboratory model

DC/DC converters
Both 12/24VDC and 24/48VDC converters are built on the base of the same boost structure (thus we
L

U Bat PWM C U DC
Current loop

C 1ON / OFF
driver
I max
Voltage loop

PI U DCref
RAMP
50kHz

Fig. 3: The boost converter and its controller

will concentrate on the first one – converter C1) and because the insulation is secured by the inverter’s
output transformer, thus in both converters there is no need to confuse with this [6, 7]. The simplified
structure together with its controller is presented in Figure 3. The 12/24VDC converter adjusts voltage
between the 12VDC battery and the DC Bus (24VDC) and as one can see its controller consists of two
loops: voltage and paramount current. Voltage loop secures stabilized and load independent output
voltage UDC only if converter’s input voltage is above its minimum value UBat-min (if UBat is below its
minimum value, then the converter is turned off; in this way this is possible to secure the battery).
Paramount current loop secures converter by limiting its peak current.
Inverter
Inverter operates in two major modes: off- and on-line. During the first one arrangement secures
sinusoidal and stabilized AC Bus voltage, while during on-line operation mode guaranties constant DC
Bus voltage (24VDC) directly and indirectly invariable 48VDC. Because to the AC Bus inverter is
connected permanently through the 24/230VAC transformer, thus this is possible to use MOSFETs to
construction. That pays off with high switching frequency (in our case 50kHz) what together with
output transformer enables utilization of the smaller size output filter [8].
Inverter’s controller consists of two loops: current and voltage. The current loop secures arrangement
against the peak current. Because in the voltage loop additionally output filter’s capacitor current is
measured, thus this is possible to determine much more quicker the instantaneous output voltage [6,
8]. This then results with shorter reaction time on load changes what during off-line operation mode
leads to load current shape independent AC Bus voltage.

L TR

C DC C
U DC u AC

drivers integrator

I max
PI G
RAMP u ACref
50kHz

Fig. 4: Inverter and its controller

Controller
Controller consists of two independent arrangements, from which first one controls 12/24VDC
converter and second one sw static switch. Concerning the principle of operation. When energy
delivered by the exercise bike generator causes the UBat battery voltage increase above the UC1ON
value, then the 12/24VDC converter is turned-on (the C1ON/OFF signal changes from low to high) and
because of that this is possible to distribute the generated energy to the DC Bus and then further (time
t1 in Fig. 5). In opposite situation, if energy supplied by the bike generator is not sufficient enough to
cover all energy needs, converter is turned-off, time t3 in Fig. 5 (in this way this is possible to secure
the battery against to low voltage level).
The second controller, on the base of DC Bus voltage measurements, turns-off or -on the sw static
switch, thus turns-off or -on the whole system. For example turning-on in time t1 converter 12/24VDC
causes the DC Bus voltage increase and when this voltage exceeds UswOFF level, then the sw static
switch will be turned-off and the whole system will work off-line. During this type of work the whole
energy delivered to the DC as well as AC loads is supplied by the battery. In situation when there is
not enough energy to cover loads needs the DC Bus voltage will drop and if reaches UDC-min level the
sw switch is turned-off and the whole system will work on-line (time t4 in Fig. 5).
One should notice that times when 12/24VDC converter is -off and sw switch is -on are different,
responsible for that is energy stored in inverter’s DC link capacitances. For the same reason moment
 U C 1ON U Bat
U C 1ON

S Q
C 1ON / OFF U Bat −min
U Bat
R Q C 1ON / OFF t
U Bat −min ON OFF
USWoff U DC t

USWoff U DC −min

U DC S Q
swON / OFF swON / OFF
R Q
ON OFF ON
U DC −min
t1 t2 t3 t4 t5 t6 t

Fig. 5: Controller and exemplary waveforms

when the whole system is off-line is delayed in relation to the moment when 12/24VDC converter is
on- (this is the time needed to complete the energy on inverter’s DC link capacitances).

Experimental results
Now this is possible to define the output electric power that is possible to achieve with build
laboratory model of the bike powered electric generator, see Figure 2. From Figure 6 this is possible to
say that for average speed of 20kph, unit produces about 250W what during one cycle of work gives
1.5kWh ready for conversion input electrical energy (above numbers are in great accuracy to the
results obtained during theoretical considerations).
Next Figures 7, 8 and 9 present selected wave-time curves for AC and DC loads, obtained during on-
and off-grid operation modes and DC Bus load changes. As one can see when starting pedaling, the DC

50W / div 2V / div

PG UG

5 kph / div 500 rpm / div

0 0
5 500

Fig. 6: Experimental characteristics, from the left generated electric power as a function of speed;
output voltage as a function of rotations

Bus voltage goes above 22VDC level and the unit switches from on- to off-grid mode. Despite of
passage from one to another operation mode, unit secures uninterrupted and unchanged amount of
supplied power. The same situation occurs during opposite change of state. Examined unit additionally
secures synchronized, uninterrupted transition and unchanged amount of delivered electrical power
during mode operation and load changes.
 Ch1 20V/div

Ch2 0.5A/div

Ch3 5A/div

Ch4 1A/div

Fig. 7: The change from PM>0 to PM=0 mode, where: Ch1 – UDC; Ch2 – iL; Ch3 – IDC; Ch4 – iM

Ch1 20V/div

Ch2 0.5A/div

Ch3 5A/div

Ch4 1A/div

Fig. 8: The change from PM=0 to PM>0 mode, where: Ch1 – UDC; Ch2 – iL; Ch3 – IDC; Ch4 – iM

Ch1 500V/div

Ch3 1A/div

Ch2 20V/div

Ch4 2A/div

Fig. 9: The DC Bus load change, where: Ch1 – uAC; Ch2 – UDC; Ch3 – iL; Ch4 – IL-DC; left side PM>0
operation mode, right side PM=0 operation mode

Costs estimation
Economic evaluation is a useful tool to determine the relative merit of the proposed system with
different characteristics, thus the results of this evaluation help to choose the alternative that is most
profitable for the considered fitness club. System consists of the following elements:
• Exercise bikes
• Alternators
• Battery
• Converter C1
• Converter C2
• Inverter
• Controller
Also, to alleviate the problem of savings variation with time, we choose to express the various cost not
in euro or other official monetary units, but in an arbitrary unit which is the cost of 10kWh = 1p.u.
Costs modeling
In this study we assumed that the cost of one exercise bike is constant, therefore in our case cost of all
bikes depends only on number of units:

C Bikes = COneBike ⋅ n (3)

where: CBikes – total cost of all bikes [p.u.]; COneBike – cost of one bike [p.u.]; n – number of units.
The cost of the alternators is proportional to the total generated electric power PG [W]:

C Alternators = PG ⋅ UC A (4)

where: CAlternators – total costs of all alternators [p.u.]; UCA – unit cost of alternator per W [p.u./W].
The cost of the battery is based on the energy capacity of battery EBatt [Ah]:

C Batt = EBatt ⋅ UC Batt (5)

where: CBatt – total costs of battery [p.u.]; UCA – unit cost of battery per Ah [p.u./Ah].
The costs of the inverter and converters are calculated on the base of the following dependency:

n
C ICs = PInv ⋅ UC Inv + ∑ PConv _ i ⋅ UCConv (6)
i =1

where: CICs – total costs of inverter and converters [p.u.]; UCInv – unit cost of inverter per W [p.u./W];
UCConv – unit cost of converter per W [p.u./W]; PInv – inverter’s power rating [W]; PConv_i – ith
converter’s power rating [W].
On the base of above the total cost of the whole exercise bike system is given by the following
equation:

CTotal = C Bikes + C Alternators + C Batt + C ICs (7)

1000
Savings [p.u.] Case 1
800 Case 2

600

400

200

-200

-400

-600

-800
Years
-1000
1 2 3 4 5 6 7

Fig. 10: Savings estimation results

 Thus the estimated costs using the basic cost assumptions (labor costs for assembly are not included;
the unit costs were determined on the base of average prices) are given in Table I.
Table I: Costs estimation
Costs [p.u.]
Case Exercise
Alternators Battery Converter C1 Converter C2 Inverter Controller Total
bikes
1 0 62.5 37.5 125 105 175 5 510
2 500 62.5 37.5 125 105 175 5 1010

On the base of given data and fact that using five bikes during one year this is possible to limit
electrical energy expenses from 480p.u. to 260p.u. – that gives savings of 220p.u. a year. Thus
depending on chosen scenario the whole investment pays-off in less than four years, see Figure 10.

Conclusions
A electric generator powered by a stationary bicycle was considered. On the base of experimental
measurements one bike generator which works with an average speed of 20kph for 6 hours a day can
produce 1.5kWh of the input electric energy. In result five generation units in average size fitness club
can cover about 45% of the whole energy consumption.
The most practical application of such unit would be battery charging and then power appliances or
tools that can perform their functions with hundreds of watts up to few kilowatts of input power,
depends on number of units. Good candidates are TVs, radios, lighting systems, backup generators for
solar electric systems, ventilation fans, pumps, watering system etc. The bike generator could be an
excellent addition to an existing battery system that may already be charged from the photovoltaic
panels, 230VAC grid power or wind power. Summarizing, a bicycle generator can be a practical
addition to an energy-conserving household or fitness club.

References
[1] Żółtowski B., Tylicki H.: Electrical equipment of the mechanical vehicles, Bydgoszcz, 1999.
[2] Halliday D., Resnick R.: Physics, Vol. 1, PWN, Warszawa, 1983.
[3] Konopiński M.: Electrical engineering in motorization, Warszawa, 1985.
[4] Kurdziel R.: Basics of electrical engineering, WNT, Warszawa, 1972.
[5] Plamitzer: Electrical drives, WNT, Warszawa, 1970.
[6] Rashid M. H. (Editor): Power electronics handbook, Academic Press, 2007.
[7] Erickson R. W., Maksimovic D.: Fundamentals of power electronics, Springer, 2001.
[8] SKVARENINA T. L. (Editor): Power electronics handbook, CRC Press, 2002.

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